Flooring apparatus

ABSTRACT

In certain embodiments, a flooring apparatus provides improved traction, improved wear resistance and improved structural support. The flooring apparatus may include an elongated member that includes a top surface and a bottom surface. The top surface may include a cutout portion that extends along at least a portion of a longitudinal axis of the elongated member. One or more inserts are positioned at least partially within the cutout portion. The insert may include a texturized top surface and may be constructed of a polymer material or other material with improved traction and, in certain embodiments, improved wear resistance.

CROSS-REFERENCE TO RELATED APPLICATIONS

Pursuant to 35 U.S.C. § 119(e), this application is a continuation ofU.S. patent application Ser. No. 14/550,783, entitled “FLOORINGAPPARATUS,” filed Nov. 21, 2014, and naming Kyle R. Gillin as aninventor, which claims priority from U.S. Provisional Application Ser.No. 61/907,830, entitled “FLOORING APPARATUS,” filed Nov. 22, 2013, andnaming Kyle R. Gillin as an inventor, all of which are incorporated byreference for all purposes.

TECHNICAL FIELD

This disclosure relates in general to a flooring apparatus and, inparticular, but not by way of limitation, to a flooring apparatus andmethod of manufacturing that includes an insert to provide, in someembodiments, improved traction, improved wear resistance, improvedstructural support, and other benefits to a floor surface.

BACKGROUND OF THE DISCLOSURE

Flooring materials are used in a wide variety of applications includingflooring for homes and other buildings, flooring for stairs and otherstructural elements, and flooring for mobile applications, such as,boats, trailers and other vehicles. The characteristics of the idealflooring material for a particular application may depend on the type ofobjects that will be placed on the flooring and the anticipatedenvironment in which the flooring will be used. In the case of flooringfor an automobile trailer, for example, the flooring may be used to holdheavy cargo, such as automobiles, construction equipment and storagecontainers, and may be exposed to the open environment for long periodsof time. Wood planks are often used on trailers to provide a lightweight and replaceable flooring onto which cargo can be placed. However,it has been found that traditional wood planks have certaindisadvantages when used as flooring.

SUMMARY

In a first aspect, there is provided a flooring apparatus that mayprovide improved traction, improved wear resistance and improvedstructural support to a floor. In some embodiments, the flooringapparatus includes an elongated member that includes a top surface, abottom surface and a cutout portion in the top surface that extendsalone at least a portion of a longitudinal axis of the elongated member.The flooring apparatus may also include an insert positioned at leastpartially within the cutout portion.

In certain embodiments, the cutout portion includes a floor, a firstside wall and a second side wall.

In other embodiments, the first side wall and the second side wallextend at an angle that is less than 90 degrees from the floor.

In another embodiment, the first side wall and the second side wallextend at an angle that is more than 90 degrees from the floor.

In yet another embodiment, the first side wall and the second side allextend at an angle that is about 90 degrees from the floor.

In still another embodiment, the first and second side walls include oneor more protrusions to secure the insert at least partially within thecutout portion.

In some embodiments, the first and second sidewalls include one or moretangs to secure the insert at least partially within the cutout portion.

In another embodiment, the floor includes one or more protrusions.

In certain embodiments, the floor includes one or more troughs to holdan adhesive used to secure the insert at least partially within thecutout portion.

In other embodiments, the flooring apparatus includes a first elongatedmember and a second elongated member, wherein a first end of the firstelongated member includes a recess and a second end of the secondelongated member includes a protrusion configured to mate with therecess when the first end of the first elongated member is in contactwith the second end of the second elongated member.

In another embodiment, the insert is constructed of a polymer material.

In certain embodiments, the insert is constructed of a recycled rubbermaterial.

In another embodiment, the elongated member is constructed of a woodmaterial.

In yet another embodiment, the wood material is a treated pine material.

In still another embodiment, a top surface of the insert is coplanarwith the top surface of the elongated member.

In some embodiments, a top surface of the insert is located above thetop surface of the elongated member.

In another embodiment, a top surface of the insert is located below thetop surface of the elongated member.

In certain embodiments, the cutout portion includes a floor, a firstside wall and a second sidewall, and the floor is located closer to thetop surface than the bottom surface of the elongated member.

In other embodiments, the cutout portion includes a floor, a first sidewall and a second sidewall, and the floor is located closer to thebottom surface than the top surface of the elongated member.

In another embodiment, the cutout portion includes a floor, a first sidewall and a second sidewall, and the floor is located about half waybetween the top surface and the bottom surface of the elongated member.

In yet another embodiment, the flooring apparatus includes one or moreattachment mechanisms to secure the insert to the elongated member.

In still another embodiment, the attachment mechanism is one of anadhesive and a mechanical fastener.

In some embodiments, the cutout portion includes a floor, a firstsidewall and a second sidewall, and the attachment mechanisms aresecured to the floor.

In another embodiment, the cutout portion includes a floor, a firstsidewall and a second sidewall, and the attachment mechanisms aresecured to the first and second sidewalls.

In certain embodiments, a top surface of the insert includes one or moreprotrusions.

In other embodiments, the elongated member and the insert are capable ofbeing colored.

In another embodiment, the flooring apparatus includes a cap located onan end of the elongated member.

In certain embodiments, an end of the elongated member is sealed.

In other embodiments, the cutout portion covers more than about 80percent of the area of the top surface of the elongated member.

In a second aspect, there is provided a trailer that includes at leastone wheel, a frame coupled to the at least one wheel and a plurality ofelongated members. In some embodiments, the frame includes a first framemember, a second frame member spaced from the first frame member, and aplurality of intermediate frame members extending between the firstframe member and the second frame member. The plurality of elongatedmembers may be supported by the intermediate frame members and theelongated members may include a top surface that includes a cutoutportion and an insert positioned at least partially within the cutoutportion.

In certain embodiments, the intermediate frame members are spacedbetween about 6 and about 24 inches from each other.

In other embodiments, the trailer includes one or more attachmentmechanisms to secure the elongated members to the frame.

In another embodiment, the trailer includes one or more attachmentmechanisms to secure the elongated members and the inserts to the frame.

In yet another embodiment, the elongated members are spaced from eachadjacent elongated member.

In a third aspect, there is provided a method of manufacturing aflooring apparatus that includes providing an elongated member thatincludes a top surface and a bottom surface, creating a cutout portionin the top surface of the elongated member, and securing an insert atleast partially within the cutout portion.

In certain embodiments, securing the insert at least partially withinthe cutout portion includes inserting an adhesive between the insert andthe cutout portion.

In other embodiments, securing the insert at least partially within thecutout portion includes applying one or more mechanical attachmentmechanisms to the insert and the elongated member.

In another embodiment, the method includes creating the insert byextruding or cutting a polymer material.

In yet another embodiment, the method includes creating one or moreprotrusions on a top surface of the insert.

In still another embodiment, the elongated member is a wood material andcreating a cutout portion in the top surface of the wood materialincludes milling the wood material.

In some embodiments, the elongated member is made of a wood material andthe method further includes treating the elongated member with achemical.

In a fourth aspect, there is provided a method of manufacturing atrailer that includes providing at least one wheel and securing the atleast one wheel to a frame that includes a first frame member, a secondframe member spaced from the first frame member, and a plurality ofintermediate frame members extending between the first frame member andthe second frame member. The method may also include providing aplurality of elongated members that have a top surface that includes acutout portion and an insert that is secured at least partially withinthe cutout portion. The method may further include securing theplurality of elongated members to at least some of the intermediateframe members.

In certain embodiments, the method includes securing at least some ofthe plurality of elongated members to one or more of the first andsecond frame members.

In other embodiments, a plurality of elongated members are secured to atleast some of the intermediate frame members by applying mechanicalfasteners to the elongated members and the intermediate frame members.

In another embodiment, the method includes spacing each elongated memberfrom the adjacent elongated members.

In yet another embodiment, the method includes coupling an end cap to anend of at least one of the elongated members.

In still another embodiment, the method includes sealing an end of atleast one of the elongated members.

In some embodiments, the method includes linking a first elongatedmember to a second elongated member such that a first end of the firstelongated member contacts a second end of the second elongated member.

In another embodiment, the first end of the first elongated memberincludes a recess and the second end of the second elongated memberincludes a protrusion that is configured to fit within the recess.

Other aspects, features, and advantages will become apparent from thefollowing detailed description when taken in conjunction with theaccompanying drawings, which are a part of this disclosure and whichillustrate, by way of example, principles of the inventions disclosed.

DESCRIPTION OF THE FIGURES

The accompanying drawings facilitate an understanding of the variousembodiments.

FIG. 1 is a perspective view of an exemplary embodiment of a flooringapparatus;

FIG. 2 is a perspective view of an embodiment of an elongated memberincluding holes in a surface of the cutout portion;

FIGS. 3A, 3B, 3C and 3D are cross-section, side views of exemplaryembodiments of an elongated member of a flooring apparatus;

FIG. 4 is a cross-section, side view of an exemplary embodiment of aflooring apparatus that includes a plurality of troughs on a floor of acutout portion;

FIG. 5A is a cross-section, side view of an exemplary flooring apparatusthat includes an attachment mechanism in a floor of the elongatedmember;

FIG. 5B is a cross-section, side view of an exemplary flooring apparatusthat includes attachment mechanisms in first and second sidewalls of theelongated member;

FIG. 6 is a perspective view of an exemplary embodiment of a flooringapparatus that includes a plurality of cutout portions;

FIG. 7A is a cross-section, side view of an exemplary flooring apparatusin which a top surface of the insert is located above a top surface ofthe elongated member;

FIG. 7B is a cross-sectional, side view of an exemplary flooringapparatus in which a top surface of the insert is located below a topsurface of the elongated member;

FIG. 8 is a perspective view of another embodiment of a flooringapparatus including a plurality of inserts oriented perpendicularly to alongitudinal axis of the elongated member.

FIG. 9 is a perspective view of another embodiment of a flooringapparatus including an insert covering an entire top surface of theelongated member.

FIG. 10A is a top view of an exemplary trailer that includes a firstframe member, a second frame member and a plurality of intermediateframe members;

FIG. 10B is a top view of an exemplary trailer that includes a pluralityof flooring apparatuses supported by the intermediate frame members;

FIG. 11 is a cross-section side view of two flooring apparatuses coupledto an intermediate frame member;

FIG. 12A is a cross-section, side view of a an embodiment of a firstelongated member positioned adjacent to a second elongated member;

FIG. 12B is a cross-section, side view of an embodiment of a firstelongated member with a first cap that is in contact with a second capof a second elongated member;

FIG. 13 is a schematic block diagram illustrating a method ofmanufacturing a flooring apparatus; and

FIG. 14 is a schematic block diagram illustrating a method ofmanufacturing a trailer using one or more flooring apparatuses.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of an exemplary embodiment of a flooringapparatus 100 that includes an elongated member 102 with a cutoutportion 104 and an insert 106 that is located at least partially withinthe cutout portion 104. As will be described in further detail below,the apparatus 100 may provide improved traction, improved wearresistance, improved structural support and other benefits to a floor.The flooring apparatus may be used as the floor of a cargo trailer, thefloor of the deck of a house, the steps of a ladder or staircase or anyother application requiring a surface.

In some embodiments, the elongated member 102 is a rectangular shape andmay be, for example, approximately 8 inches by 2 inches by several feetor more. In other embodiments, the elongated member 102 may be larger orsmaller than 8 inches by 2 inches. The elongated member 102 may beconstructed of any suitable material, for example, wood, metal and/orplastic, or any suitable combination of materials. In some embodiments,for example, the elongated member 102 is made of a treated woodmaterial, such as a treated pine. In some embodiments, the elongatedmember 102 is made of Treated Southern Yellow Pine. The elongated member102 may be made of other wood materials in other embodiments. In someembodiments, for example, the elongated member 102 is made of DouglasFir, Hem Fir or SPF (spruce-pine-fur). In yet other embodiments, theelongated member 102 is made of Canadian SPF.

In some embodiments, the elongated member 102 may be constructed of awood material that is specifically chosen for its non-warpingcharacteristics so that it is less prone to warp over time. In someembodiments, for example, the elongated member 102 is chosen such thatthe growth rings 154 are curved away from the cutout portion 104, asshown in the embodiment illustrated in FIG. 1. In some embodiments, theorientation of the growth rings away from the cutout portion 104counteracts possible upward curling of the elongated member 102 due tothe cutout portion 104.

In some embodiments, the color of the elongated member 102 can bechanged, for example, by staining or painting the elongated member 102.In some embodiments, the elongated member 102 and the insert 106 areboth made of materials whose color can be changed so that the color ofthe elongated member 102 can be matched to the color of the insert 106.In other embodiments, the color of the elongated member 102 and thecolor of the insert 106 do not match. In some embodiments, a coloredpigment or other material, such as an ethylene propylene diene monomer(EPDM) material, is added to the material from which the insert 106 ismade (such as a rebonded rubber) to give the insert 106 a particularcolor. For example, in some embodiments a pigment is added to the basepolymer from which the insert 106 is made. The insert 106 can be anysuitable color based on the pigment, paint or other material that isadded to the insert 106 during its formation.

In some embodiments, the elongated member 102 includes a cutout portion104 that extends along at least a portion of a longitudinal axis 108 ofthe elongated member 102. As will be described in more detail below, thecutout portion 104 may be any suitable shape and in some embodimentsincludes a first sidewall 110, a second sidewall 112 and a floor 114.

In some embodiments, the cutout portion 104 is sized and shaped to holdat least a portion of the insert 106. The insert 106 may be any suitablesize and shape that can be at least partially located in the cutoutportion 104. For example, in some embodiments the insert 106 isrectangular in shape. In some embodiments, a top surface 132 of theinsert 106 may be substantially flat or may be curved, for example, in aprotruding, convex shape. The surfaces of the insert 106 may contact thesidewalls 110 and 112 and floor 114 of the cutout portion or may notcontact one or more of the sidewalls 110 and 112 and/or the floor 114.In some embodiments, for example, the insert 106 has a curved bottomsurface 156 and only a portion of the bottom surface 156 contacts thefloor 114 or the sidewalls 110 and 112.

In some embodiments, the insert 106 is slightly smaller than the cutoutportion 104 to allow for variations in the rate at which the insert 106and the elongated member 104 expand and contract over time. For example,in some embodiments the elongated member 104 and the insert 106 mayexpand and contract at different rates as a result of variations inambient temperature. In some embodiments, the insert 106 is held in acentered orientation in the cutout portion 104 by one or more couplingdevices (see e.g., the coupling device 130 of FIG. 5A). In someembodiments, the coupling devices 130 maintain the insert 106 in acentral location in the cutout portion 104 while allowing the insert 106to expand/contract within the cutout portion 104.

The surfaces of the insert 106 may also include a texture, such as, forexample, a series of protrusions and recesses (not shown in FIG. 1), toincrease the traction of the surfaces of the insert 106. In someembodiments, the surfaces of the cutout portion 104 may also include asurface texture.

Referring now to FIG. 2, in some embodiments the cutout portion 104includes holes 158 in the floor 114 to provide additional surface areato which an adhesive is coupleable to secure the insert 106 (FIG. 1) tothe cutout portion 104. For example, in some embodiments an adhesive(see e.g., the adhesive 126 shown in FIG. 4) is used to couple theinsert 106 (FIG. 1) to the cutout portion 104 and the adhesive 126provides the strongest coupling strength at the location of the holes158 due to the increased depth of the adhesive 126 contained within theholes 158. In some embodiments, the first and second sidewalls 110 and112 of the cutout portion 104 also include holes 158. In someembodiments, the insert 106 also includes holes (not shown) to allow forthe adhesive 126 to enter the holes and further secure the insert 106 tothe cutout portion 104.

Referring again to FIG. 1, the insert 106 may be made of any suitablematerial. In some embodiments, the insert 106 may be made of a polymermaterial that has a high frictional coefficient, such as a rubbermaterial. In some embodiments, the insert 106 may be made of a recycledrubber material, such as a material made from recycled tire material. Insome embodiments, the insert 106 may include colored pigments and inother embodiments may be made of one or more of a rebonded rubbermaterial, a vulcanized rubber material and/or an extruded rubbermaterial, such as, for example, RUMBER® flooring material manufacturedby Rumber Materials, located in Muenster, Tex.

FIGS. 3A-3D show cross-sectional, side views of exemplary embodiments ofthe elongated member 102 and the cutout portion 104. In the embodimentof FIG. 3A, for example, the cutout portion 104 is rectangular andincludes a first sidewall 110 and a second sidewall 112 that extendsfrom a floor 114 at an angle 160 that is about 90 degrees. In theembodiment of FIG. 3B, the first sidewall 110 and the second sidewall112 extend at an angle 160 that is less than about 90 degrees from thefloor 114. In the embodiment of FIG. 3C, the first sidewall 110 and thesecond sidewall 112 extend at an angle 160 that is more than about 90degrees from the floor 114. In the embodiment of FIG. 3D, the firstsidewall 110 and the second sidewall 112 extend at an angle 160 of abouta 90 degrees from the floor 114 and include a plurality of tangs 116, aswill be described in more detail below.

The cutout portion 104 may be symmetric about a centerline 118 of theelongated member 102, as shown in FIGS. 3A-3D, or may be asymmetricabout the centerline 118 (not shown). The cutout portion 104 may have aconstant cross-sectional shape along the longitudinal axis 108 of thecutout portion 104 or may have various cross-sectional shapes along thelongitudinal axis 108 of the cutout portion 104.

The cutout portion 104 may also be any suitable size with respect to theelongated member 102. In some embodiments, for example, the cutoutportion 104 occupies about 80 percent of the top surface 120 of theelongated member 102. As such, when the insert 106 is placed within thecutout portion 104, the insert 106 may also cover up to about 80 percentof the top surface 120 of the elongated member 102. In some embodiments,the cutout portion 104 occupies more than about 80 percent of the topsurface 120 of the elongated member 102 (or more than about 80 percentof the width of the top surface 120) and, when the insert 106 is placedwithin the cutout portion 104, the insert 106 may also cover more thanabout 80 percent of the width or entirety of the top surface 120 of theelongated member 102. In other embodiments, the cutout portion 104occupies less than about 80 percent of the top surface 120 (or less thanabout 80 percent of the width of the top surface 120) of the elongatedmember 102 and, when the insert 106 is placed within the cutout portion104, the insert 106 may also occupy less than about 80 percent of thewidth or the entirety of the top surface 120 of the elongated member102.

The cutout portion 104 may also have any suitable surface texturing tohelp secure the insert 106 within the cutout portion 104. For example,referring again to the embodiment of FIG. 3A, the first and secondsidewalls 110 and 112 or the floor 114 may include a plurality ofprotrusions 124 or surface texture to help secure the insert 106 atleast partially within the cutout portion 104. In the embodiment of FIG.3B, the angle 160 at which the first and second sidewalls 110 and 112extend with respect to the floor 114 may help secure the insert 106 atleast partially within the cutout portion 104. In the embodiment of FIG.2D, the first and second sidewalls 110 and 112 may include a pluralityof tangs 116 or other protrusions to help secure the insert 106 at leastpartially within the cutout portion 104.

Other surface texturing or modifications to the cutout portion 104and/or the insert 106 may be used to further secure the insert 106 atleast partially within the cutout portion 104. For example, in someembodiments, the insert 106 may include protrusions (not shown) thatmate with corresponding recesses (not shown) in the cutout portion 104so that the insert 106 may be “snapped” into place in the cutout portion104.

In some embodiments, additional mechanisms may be coupled to theelongated member 102 and the insert 106 to further secure the insert 106at least partially within the cutout portion 104. For example, in theembodiment of FIG. 4 an adhesive 126 is located in the cutout portion104 to secure the insert 106 (not shown) to the floor 114 of the cutoutportion 104. The adhesive 126 may be any suitable adhesive. For example,in some embodiments the adhesive is CHEMREX® CX-948 or CX-941, both madeby BASF, located in Shakopee, Minn., USA. In some embodiments, theadhesive is one or more of HYBOND® 80 PLUS, made by Hybond located atLongden, Shrewsbury, United Kingdom; LOCTITE® PL® 500 Landscape BlockAdhesive, made by Loctite located at Westlake, Ohio; FORTANE LD® WoodFlooring Urethane Adhesive, made by Fortane located at Indianapolis,Ind.; and HENRY® 440 Cove Base Adhesive, made by The W.W. Henry Companylocated at Aliquippa, Pa.

Referring still to FIG. 4, in some embodiments the elongated member 102includes a plurality of troughs 128 in the floor 114 of the cutoutportion 104 to hold an adhesive 126. In some embodiments, the troughs128 may allow for expansion and contraction of the adhesive 126according to weather conditions or other factors. In some embodiments,the troughs 128 allow for a greater depth or thickness of adhesive toreside between the insert 106 and the floor 114 of the cutout portion104 which may increase the strength of the bond between the insert 106and the floor 114. In addition, the cutout portion 104 may include otherfeatures, such as holes 158 of FIG. 2, to increase the effectiveness ofthe adhesive 126 between the insert 106 and the floor 114.

FIG. 5A is a cross-sectional, side view of an exemplary flooringapparatus 100 that includes an attachment mechanism 130 extending fromthe bottom surface 122 of the elongated member 102 through the floor 114of the elongated member 102 to further secure the insert 106 at leastpartially within the cutout portion 104. The attachment mechanism 130may be any suitable attachment mechanism, such as, for example, a nailor a screw. While the attachment mechanism 130 in FIG. 5A extends fromthe bottom surface 122 of the elongated member 102 upward to the insert106, the attachment mechanism 130 may be located in any suitableposition. For example, in some embodiments, the attachment mechanism 130extends from a top surface 132 of the insert 106 downward through thefloor 114 of the elongated member 102. The apparatus 100 may include aplurality of attachment mechanisms 130 spaced periodically throughoutthe insert 106. As described above, the attachment mechanisms 130 maykeep the insert 106 at least partially within the cutout portion 104 inthe case of expansion or contractions of one or more of the insert 106or the elongated member 102.

The first and second sidewalls 110 and 112 may also be coupled to theinsert 106 by attachment mechanisms 130. For example, FIG. 5B is across-sectional, side view of an exemplary flooring apparatus 100 thatincludes attachment mechanisms 130 in the first and second sidewalls 110and 112 of the elongated member 102.

FIG. 6 is a perspective view of a flooring apparatus 100 with anelongated member 102 that includes a plurality of cutout portions 104extending along the longitudinal axis 108 of the elongated member 102.As shown in FIG. 6, the cutout portions 104 may be spaced from eachother along the longitudinal axis 108. Each of the cutout portions 104may include an insert 106 and, in some embodiments, each of the cutoutportions 104 may include a plurality of inserts 106. The inserts 106 maybe secured within the cutout portions 104 by an adhesive, one or moreattachment mechanisms 130, or some other securing method or combinationof methods or mechanisms.

Referring now to FIG. 7A, in some embodiments the insert 106 may bepartially or fully located within the cutout portion 104. In someembodiments, a top surface 132 of the insert 106 is located above thetop surface 120 of the elongated member 102, as shown in FIG. 7A. Inother embodiments, the top surface 132 of the insert 106 is locatedbelow the top surface 120 of the elongated member 102, as shown in FIG.7B. In some embodiments, the top surface 132 of the insert 106 iscoplanar with the top surface 120 of the elongated member 102, as shownin FIG. 1. Although the top surface 132 of the insert 106 is shown inFIGS. 7A and 7B as a flat surface, the top surface 132 may have anysuitable shape and may be, for example, semi-circular in shape so thatportions of the top surface 132 are below the top surface 120 andportions of the top surface 132 are above the top surface 120.

The insert 106 and the cutout portion 104 may also extend to anysuitable depth in the elongated member 102. For example, in theembodiment shown in FIG. 6A the floor 114 of the cutout portion 104 islocated closer to the bottom surface 122 of the elongated member 102than the top surface 120 of the elongated member 102 and the insert 106is tall enough to contact the floor 114 and to protrude above the topsurface 120 of the elongated member 102. In the embodiment of FIG. 6B,the floor 114 is located closer to the top surface 120 of the elongatedmember 102 than the bottom surface 122 of the elongated member 102 andthe insert 106 does not protrude from the top surface 120 of theelongated member 102 when the insert 106 is in contact with the floor114. In other embodiments, the floor 114 may be located about half waybetween the top surface 120 and the bottom surface 122 of the elongatedmember 102. In some embodiments, the floor 114 may be located about ⅜inch from the top surface 120. In some embodiments, the floor 114 may belocated about ½ inch from the top surface 120. In addition, while theinsert 106 is shown to contact the floor 114 of the cutout portion 104in the embodiments of FIGS. 7A and 7B, in some embodiments the insert106 does not contact the floor 114 and/or one or more of the sidewalls110 or 112. In other embodiments, the insert 106 may contact onlyportions of the floor 114 and/or the sidewalls 110 and 112.

Referring now to FIG. 8, in some embodiments the cutout portions 104 areoriented perpendicularly to the longitudinal axis 108 of the elongatedmember 102 or, in other embodiments not specifically shown, at an angleoffset from the longitudinal axis 108 of the elongated member 102. Insome embodiments, the elongated member 102 includes a plurality ofperpendicularly-situated cutout portions 104 that each include at leastone insert 106. In some embodiment, a distance 164 between cutoutportions 104 is about twice the width 166 of the cutout portions 104.

In some embodiments, the cutout portions 104 extend through thesidewalls 168 of the elongated member 102, as shown in FIG. 8. In otherembodiments, the cutout portions 104 do not extend through the sidewalls168 of the elongated member 102.

Referring now to FIG. 9, in some embodiments the cutout portion 104extends across the entire top surface of the elongated member 102. Insome embodiments, the insert 106 is coupled to the cutout portion 104and is co-extensive with the elongated member 102, as shown in FIG. 9.The insert 106 may be secured to the elongated member 102 by one or morefastening mechanisms 130, an adhesive 126 (not shown), or a combinationof fastening mechanisms 130 and adhesives 126.

In other embodiments, the elongated member 102 does not include a cutoutportion 104 and the insert 106 is coupled directly to the top of theelongated member 102. This embodiment looks similar to the embodimentdepicted in FIG. 9 except that the elongated member 102 will be thickerbecause it has not been cut to form a cutout portion 104. The insert 106may be secured to the elongated member 102 by one or more fasteningmechanisms 130, an adhesive 126, or a combination of fasteningmechanisms 130 and adhesives 126

FIG. 10A is a top view of an exemplary trailer 200. The trailer 200generally includes a first frame member 202, a second frame member 204,a plurality of intermediate frame members 206 and two wheels 208 thatare rotatably secured to or adjacent to the frame members 202, 204and/or 206. The first frame member 202 is spaced from the second framemember 204 according to the desired width of the trailer 200. Theintermediate frame members 206 extend between and are coupled to thefirst frame member 202 and the second frame member 204. Other framemembers may be included in the trailer 200 in other embodiments. Inaddition, other trailers 200 may include other frame configurations. Thetrailer 200 is given only by way of example and is not intended to belimiting to this disclosure.

In some embodiments, the intermediate frame members 206 are spaced apartfrom each other by a distance of about 12 inches. In other embodiments,the distance between the intermediate frame members 206 is more or lessthan 12 inches. For example, in some heavy-duty trailers 200 theintermediate frame members 206 are spaced apart from each other by adistance of about 6 inches. In some embodiments, the spacing of theintermediate frame members 206 is determined by the weight requirementsof the trailer 200 and the structural strength of the material used tocreate the trailer floor, as will be described in more detail below.

While the intermediate frame members 206 are perpendicular to the firstand second frame members 202 and 204 in the embodiment illustrated inFIGS. 10A and 10B, the intermediate frame members 206 may be positionedat any suitable orientation to the first and second frame members 202and 204. In addition, while the first and second frame members 202 and204 are parallel to each other, the first and second frame members 202and 204 may be orientated at any suitable angle and, in someembodiments, may contact each other. Those of skill in the art willrecognize that other trailer frame orientations are within the scope ofthis disclosure.

FIG. 10B is a top view of an exemplary trailer 200 that includes aplurality of flooring apparatuses 100 that extend generally from one endto the other end of the trailer 200 to form the floor of the trailer 200and are supported by intermediate frame members 206. In otherembodiments, the flooring apparatuses 100 do not extend the entirety ofthe length of the trailer 200, and/or the width of the trailer 200.While seven flooring apparatuses 100 are shown in the embodiment of FIG.10B, the floor of the trailer may be formed by any number of flooringapparatuses 100. In addition, while the flooring apparatuses 100 areoriented, in this embodiment, perpendicularly to the intermediate framemembers 206, the flooring apparatuses 100 may be oriented in anysuitable angle to the intermediate frame members 206, not expresslyshown in FIG. 10B.

As described above, the flooring apparatuses 100 may be configured tosupport cargo that is placed on a trailer 200. The flooring apparatus100 may, in some instances, provide improved traction, improved wearresistance and improved structural support for the trailer floor. Insome embodiments, for example, the cutout portion 104 covers a highpercentage of the top surface 120 of the elongated member 102 (forexample, about 80 percent of the top surface 120). As such as, theinsert 106 may also cover a high percentage of the top surface 120 ofthe trailer floor. As a result, cargo that is placed on the trailerfloor contacts mostly the top surface 132 of the inserts 106, which hasincreased traction and increased wear resistance.

The top surface 120 of the inserts 106 may also have a high coefficientof friction. Thus, in some embodiments the apparatuses 100 that form thetrailer floor provide increased traction for objects placed on thetrailer 200. For example, in some embodiments, a user may drive abackhoe or other piece of construction equipment onto the trailer floorwhen the trailer floor is inclined, such as on a dovetail trailer or akneeling trailer. The increased traction of the top surface 132 of theinserts 106 provides increased traction to prevent the tires of thebackhoe from slipping while driving up an inclined surface of thetrailer 200. The increased traction of the top surface 120 of theinserts 106 may also assist in wet conditions, including when theapparatuses 100 are used as the flooring of an outdoor scaffolding.

In addition, in some embodiments the increased wear resistance of thetop surface 132 of the inserts 106 may guard against wear anddeterioration if the trailer 200 is left outside for long periods oftime. As such, the trailer 200 may remain intact and/or aestheticallypleasing for a longer period of time when compared to trailers made withother flooring materials.

As described above, in some embodiments at least a portion of the topsurface 120 (FIG. 1) of the elongated member 102 is exposed on thetrailer floor adjacent to the insert 106. Thus, a portion of the weightof an object that is placed on the trailer 200 is supported by theelongated member 102 rather than being supported directly by the insert106. In some embodiments, the elongated member 102 has a higherstructural strength than the insert 106 and, thus, the flooringapparatus 100 may be able to support heavier objects than would bepossible if the entire elongated member 102 were made of a rubber orother wear resistant material.

In addition, in those embodiments in which the cutout portion 104 doesnot cover the entire top surface 120 of the elongated member 102, anobject on the trailer 200 contacts both the insert 106 and the topsurface 120 of the elongated member 102 simultaneously. Thus, forcesapplied to the apparatus 100 by the object on the trailer are appliedsimultaneously to the insert 106 and the top surface 102 of theelongated member 102. In some embodiments, this reduces the chance thatthe insert 106 may be torn from the cutout portion 104.

In some embodiments, the apparatuses 100 are sufficiently strong thatthe trailer 200 requires fewer intermediate frame members 206 to supporta particular object on the trailer 200. Thus, in some embodiments thecost to build the trailer 200 and the overall weight of the trailer 200can be reduced when using the apparatus 100.

FIG. 11 is a cross-sectional side view of two flooring apparatuses 100coupled to an intermediate frame member 206 by attachment mechanisms130. In some embodiments, the attachment mechanisms 130 secure both theelongated member 102 and the insert 106 to the intermediate frame member206 by extending at least partway through both the elongated member 102and the insert 106, as shown in FIG. 11. In some embodiments, theattachment mechanisms 130 secure only the elongated member 102 to theintermediate frame member 206 by extending only partway through theelongated member 102 and not into the insert 106.

While the attachment mechanism 130 shown in FIG. 11 is a mechanicalattachment mechanism, any suitable attachment mechanism or combinationof attachment mechanisms may be used to secure the apparatuses 100 tothe a support structure, such as the frame members 206 of a trailer 200.In other embodiments, for example, the apparatuses 100 are secured to asupport structure by one or more adhesives, a welded attachment, screws,nails and/or bolts.

As shown in FIG. 11, the flooring apparatuses 100 may be spaced fromeach other when secured to a support structure, such as the intermediateframe member 206. Spacing the flooring apparatuses 100 in this mannermay reduce the number of apparatuses 100 required to cover a floor area.

FIG. 12A is a cross-sectional, side view of a first elongated member 146positioned adjacent to a second elongated member 148. In someembodiments, multiple elongated members 148 are placed adjacent to eachother (i.e., end-to-end) when a single elongated member 102 is notsufficiently long to cover a desired surface, such as a trailer surface.In those embodiments, the elongated members 102 may simply be placed endto end or the elongated members 102 may include a feature to interlockand align the elongated members 102. For example, in some embodiments afirst elongated member 146 includes a recess 136 on a first end 138 anda second elongated member 148 includes a protrusion 142 on a second end140. The protrusion 142 corresponds in shape to the recess 136 so thatthe protrusion 142 and recess 136 help to align the first and secondelongated members 146 and 148. In some embodiments, interlockingengagement of the protrusion 142 and the recess 136 also at leastpartially seals the intersection of the first and second elongatedmembers 146 and 148 to prevent contaminants from entering between thefirst and second elongated members 146 and 148.

FIG. 12B is a cross-sectional, side view of another embodiment of twoelongated members 150 and 152 that are aligned end-to-end. The first andsecond elongated members 150 and 152 each include a cap 144 that protectthe ends of the elongated members 150 and 152 and the inserts 106 (notshown) from environmental contaminants. In some embodiments, the caps144 also include mating recesses and grooves (not shown), similar to therecess 136 and groove 142 described above, to align the elongatedmembers 150 and 152.

While the above description illustrates the use of the apparatus 100 ona trailer 200, the apparatus 100 can also be used as a flooring elementfor many other types of floors and support structures. For example, theflooring apparatuses 100 can be used as the flooring for a deck of ahome, as a safety flooring material for an industrial application, suchas an offshore drilling rig, as a material for steps of a staircase, oras flooring on scaffolding, walkways or other elevated pathways. One ofskill in the art will recognize other suitable uses for the apparatus100.

Referring now to FIG. 13, an embodiment of a method 300 of manufacturinga flooring apparatus 100 is illustrated. The method 300 includesproviding an elongated member 102 that includes a top surface 120 and abottom surface 122, as provided at block 302. The elongated member 102may be made of any suitable material, as described above, and may besimilar to the elongated member shown in FIG. 1. In some embodiments,the elongated member 102 is made of a wood material, such as pine, andthe method 300 includes treating the material of the elongated member102, as provided at block 304. For example, in some embodiments a woodenelongated member 102 is treated with a chemical, such as, for example,WOLMAN®, made by Lonza, located in Basel, Switzerland. In otherembodiments, the elongated member 102 is treated by another suitabletreatment chemical or treatment method. For example, in someembodiments, the elongated member 102 is made of wood and is treatedwith a borate material to form a borate treated wood piece, such as, forexample, SILLBORE Borate-Treated Wood made by Lonza, located in Basel,Switzerland. In other embodiments, a wooden elongated member 102 istreated with micronized copper azole (MCA) and/or micronized copperquaternary (MCQ) materials.

A cutout portion 104 is then created in the top surface 120 of theelongated member 102, as provided at block 306. In some embodiments, thecutout portion 104 is made by milling a portion of a wooden elongatedmember 102. As described above, the cutout portion 104 may extend theentire length of the elongated member 102 or may extend less than theentire length of the elongated member 102. The elongated member 102 mayinclude any number of cutout portions 104 and the cutout portions 104may extend perpendicular to, parallel to, or at another angle withrespect to the longitudinal axis 108 of the elongated member 102.

The method 300 may also include securing one or more inserts 106 atleast partially within the cutout portion 104, as provided at block 308.The inserts 106 may be created by extruding a rubber material, cutting amaterial from a large, pre-formed sheet of the material, molding amaterial, or any other suitable forming process or combination ofprocesses. In some embodiments, for example, the insert 106 is made fromrebonded rubber (i.e., rubber that has been recycled using heat,pressure and a urethane bonding agent) which, in some embodiments,includes one or more pigments to produce an insert 106 of a particularcolor. In some embodiments, the rebonded rubber material is formed intosheets that are then cut into the shape of the insert 106. In someembodiments, surface texture is also added to the surfaces of the insert106, for example, by stamping a texture onto the surfaces of the insert106. In some embodiments, a pigment or other coloring agent is appliedto the inserts 106, included in the raw materials used to make theinserts 106 or otherwise incorporated into the inserts 106 to give theinserts 106 a desired color. In some embodiments, the color of theinserts 106 matches the color of the elongated member 102, while inother embodiments the color of the inserts 106 does not match the colorof the elongated member 102.

The inserts 106 may be fixed in the cutout portion 104 by inserting anadhesive 126 between the inserts 106 and the cutout portion 104, asprovided at block 310. In some embodiments, the inserts 106 may also besecured to the cutout portion 104 by applying one or more mechanicalattachment mechanisms to the insert 106 and the elongated member 102,such as, for example, nails, screws or bolts.

Referring now to FIG. 14, a method 400 of manufacturing a trailer 200using one or more flooring apparatuses 100 is also described herein. Insome embodiments, the method 400 includes providing at least one wheel208 and securing the wheel 208 to a frame member 202, 204 or 206 or in aposition adjacent to a frame member 202, 204 or 206, as provided atblocks 402 and 404, respectively. As described above, the frame mayinclude a first frame member 202, a second frame member 204 spaced fromthe first frame member 202, and a plurality of intermediate framemembers 206 extending between the first frame member 202 and the secondframe member 204. The frame members 202 and 204 and the intermediateframe members 206 may be secured to each other by any suitableattachment mechanism or combination of attachment mechanisms, such as,for example, a welded attachment and/or mechanical fasteners. Thetrailer 200 may include any suitable configuration of frame members 202,204 and 206. For example, in some embodiments the intermediate framemembers 206 extend only partway between the first and second framemembers 202 and 204 and the trailer 200 includes sheet metal or othersupport materials to form part of the floor of the trailer 200.

The method 400 may also include providing a plurality of elongatedmembers 102 that include a top surface 120 that has a cutout portion 104and an insert 106, as provided at block 406. The elongated members 102may be secured to the intermediate frame members 206, the first and/orsecond frame members 202 and 204, and/or any other portion of thetrailer 200 by any suitable attachment mechanisms, such as for example,mechanical fasteners such as bolts, screws or nails, as provided atblock 408. Each elongated member 102 may be spaced from the adjacentelongated members 102 or may be placed directly adjacent to otherelongated members 102. In some embodiments, an end of the elongatedmembers 102 may be sealed, for example, by securing an end cap 144 onthe end of the elongated member 102. In some embodiments, a firstelongated member 102 may be aligned with a second elongated member 102(i.e., an end-to-end alignment) if the elongated members 102 are not belong enough to cover the trailer 500. As described above, the first end138 of the first elongated member 102 may include a recess 136 and thesecond end 140 of the second elongated member 102 may include aprotrusion 142 that is configured to fit within the recess 136.

In the foregoing description of certain embodiments, specificterminology has been resorted to for the sake of clarity. However, thedisclosure is not intended to be limited to the specific terms soselected, and it is to be understood that each specific term includesother technical equivalents which operate in a similar manner toaccomplish a similar technical purpose. Terms such as “left” and right”,“front” and “rear”, “above” and “below” and the like are used as wordsof convenience to provide reference points and are not to be construedas limiting terms.

In this specification, the word “comprising” is to be understood in its“open” sense, that is, in the sense of “including”, and thus not limitedto its “closed” sense, that is the sense of “consisting only of”. Acorresponding meaning is to be attributed to the corresponding words“comprise”, “comprised” and “comprises” where they appear.

In addition, the foregoing describes only some embodiments of theinvention(s), and alterations, modifications, additions and/or changescan be made thereto without departing from the scope and spirit of thedisclosed embodiments, the embodiments being illustrative and notrestrictive.

Furthermore, invention(s) have been described in connection with whatare presently considered to be the most practical and preferredembodiments, it is to be understood that the invention is not to belimited to the disclosed embodiments, but on the contrary, is intendedto cover various modifications and equivalent arrangements includedwithin the spirit and scope of the invention(s). Also, the variousembodiments described above may be implemented in conjunction with otherembodiments, e.g., aspects of one embodiment may be combined withaspects of another embodiment to realize yet other embodiments. Further,each independent feature or component of any given assembly mayconstitute an additional embodiment.

What is claimed is:
 1. A flooring apparatus, comprising: an member thatincludes a top surface and a bottom surface, wherein the top surfacecomprises a cutout portion that extends along at least a portion of themember; and a friction-increasing insert positioned at least partiallywithin the cutout portion and secured to the cutout portion, wherein atleast a portion of the insert is vertically offset from the top surfaceof the member.
 2. The flooring apparatus according to claim 1, whereinthe cutout portion includes a floor, a first sidewall and a secondsidewall, and wherein at least one of the first and second sidewalls andthe floor of the cutout portion comprise a plurality of holes to receivean adhesive therein.
 3. The flooring apparatus according to claim 1,wherein the first sidewall and the second sidewall extend at about aninety degree angle from the floor.
 4. The flooring apparatus accordingto claim 1, wherein the member comprises a wood material comprisinggrowth rings curved away from the cutout portion wherein an orientationof the growth rings counteracts a curling of the member.
 5. The flooringapparatus according to claim 1, wherein the cutout portion comprises afloor, a first sidewall and a second sidewall, and wherein the floor islocated closer to the top surface of the member than the bottom surfaceof the member.
 6. The flooring apparatus according to claim 1, furthercomprising one or more attachment mechanisms to secure the insert to thecutout portion, wherein the one or more attachment mechanisms compriseat least one of an adhesive and a mechanical fastener.
 7. The flooringapparatus according to claim 1, wherein the portion of the insertprotrudes above the top surface of the member.
 8. The flooring apparatusaccording to claim 1, wherein at least a portion of the at least aportion of the insert sits below the top surface of the member and doesnot protrude beyond the top surface of the member and does not protrudebeyond the bottom surface of the member.
 9. The flooring apparatusaccording to claim 1, wherein the portion of the friction-increasinginsert that is vertically offset from the top surface of the membercomprises an insert top surface comprising an at least partiallyprotruding convex shape.
 10. The flooring apparatus according to claim1, wherein the insert top surface is configured to compress wherein anobject resting on the flooring apparatus contacts both the insert topsurface and the member simultaneously.
 11. The flooring apparatusaccording to claim 1, wherein the insert top surface is provided at alevel relative to the member, and wherein the insert top surface isprovided at a different level when an object contacts both the insertand the member simultaneously.
 12. The flooring apparatus according toclaim 1, wherein the insert comprises an ethylene propylene dienemonomer material comprising a color pigment distributed with a polymer.13. A method of manufacturing a flooring apparatus, the methodcomprising: providing a member comprising a top surface and a bottomsurface; creating a cutout portion extending at least partially in thetop surface of the member; and securing an insert at least partiallywithin the cutout portion, wherein securing the insert at leastpartially within the cutout portion comprises inserting an adhesivebetween the insert and the cutout portion.
 14. The method according toclaim 13, wherein at least a portion of the insert is vertically offsetfrom the top surface of the member.
 15. The method according to claim13, wherein securing the insert at least partially within the cutoutportion comprises applying one or more mechanical attachment mechanismsto the insert and the member.
 16. The method according to claim 13,further comprising creating the insert by extruding or cutting a polymermaterial.
 17. The method according to claim 13, wherein another portionof the insert protrudes above the top surface of the member.
 18. Themethod according to claim 13, wherein another portion of the insert sitsbelow the top surface of the member.
 19. A flooring apparatus,comprising: an member that includes a top surface and a bottom surface,wherein the top surface comprises a cutout portion, wherein the cutoutportion comprises a trough having a first trough depth measured from thetop surface to a floor of the trough, wherein the trough is formed alongat least a portion of the top surface of the member; and afriction-increasing insert positioned at least partially contacting thetop surface of the member and at least partially covering the cutoutportion of the member and secured to the cutout portion, wherein atleast a portion of the friction-increasing insert is spaced a firsttrough depth apart from the floor of the trough and forms a cavitybounded between the friction-inserting insert and the floor of thetrough on a first two sides, and between sidewalls of the cavity on afurther two sides.
 20. The flooring apparatus according to claim 19,wherein the member is elongate and the cutout portion extends along atleast a portion of a longitudinal axis of the member, wherein at least aportion of the friction-increasing insert is adhered to the cutoutportion by adhesive within the cavity between the friction-insertinginsert and the floor of the trough.